Pressed paper cut-in-place die

ABSTRACT

A die system ( 10 ) for cutting a piece of sheet stock ( 11 ) to create a blank and forming the blank to create a container includes first and second mating die halves ( 56, 96 ) and a cutting punch ( 68 ). The first and second mating die halves ( 56, 96 ) are configured to move together to form the container from the blank. The cutting punch ( 68 ) extends about the first die half ( 56 ) and is movable therewith. The cutting punch ( 68 ) is configured to cut the piece of sheet stock ( 11 ) to create the blank. Movement of the die halves ( 56, 96 ) together causes the cutting punch ( 68 ) to cut the blank from the piece of sheet stock ( 11 ) and further movement of the die halves ( 56, 96 ) together causes the first and second die halves ( 56, 96 ) to form the container from the blank.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a U.S. national counterpart application ofinternational application serial No. PCT/US98/25434 filed Dec. 1, 1998,which claims priority to U.S. provisional application serial No.60/067,425 filed Dec. 3, 1997.

BACKGROUND AND SUMMARY OF THE INVENTION

The present invention relates to pressed paperboard forming machines,and particularly to pressed paper cut-in-place dies for forming papercontainers and the like.

Most of the pressed paperboard forming machines currently in productionconsist of one of three processes. In the first, the paperboard blank isprecut on a separate machine and the stack of blanks are then placedinto a hopper on the forming machine whereby they are then fed one at atime into a forming section. In the forming section, the blank is dockedagainst physical stops which centers the blank over matched, metal maleand female die halves. The top die which is usually the male die thendescends engaging the paper and forcing it into the female cavity. Themale die presses the paperboard against the female die for a period oftime, then begins to ascend to an open position. An ejector mechanism inthe female die lifts the container out of the female die and because thefemale die is on an acute angle, the container falls out of the die andpress onto a conveyor. In some machines in the past, the dies have beenarranged to form the paper plate or container upside down.

In the second system, a web of paperboard is unwound from a a roll andfed into a press comprised of three sections; a feed or meteringsection, a cutting or blanking section, and a forming section. In thistype system, the feed section meters the paperboard into the cuttingsection over a female cavity or hole. The top platen which contains malepunches that match the size of the female cavity or hole in the bottomthen descends and shears the paperboard blanks from the web. The blanksthen drop through the hole and are transferred to the forming section bysliding via gravity on rails set to 45° angles. In the forming section,the blank is docked against physical stops which centers the blank overmatched, metal male and female die halves. The top die which is usuallythe male die then descends engaging the paper and forcing it into thefemale cavity. The male die presses the paperboard against the femaledie for a period of time, then begins to ascend to an open position. Anejector mechanism in the female die lifts the container out of thefemale die and because the female die is on a 45° angle, the containerfalls out of the die and press onto a conveyor.

The third system consists of feeding a web of paperboard into a cuttingsection that utilizes a steel rule die to cut and crease the blankssimultaneously. Although the blanks have been cut from the web, they arestill attached to the web by small nicks in the paperboard. The paper isthen indexed with the blank intact until it exits the cutting section.As the web with the pre-cut blank exits the cutting section, a set ofrollers picks up the blank and strips it from the web. The scrap exitsthe bottom of the machine and is cut into pieces as the blank is urgedby the rollers into the forming die section. In the forming section, theblank is docked against physical stops which centers the blank overmatched, metal male and female die halves. The top die which is usuallythe female die then descends engaging the paper and forcing it aroundthe male die. The female die presses the paperboard against the male diefor a period of time, then begins to ascend to an open position. As thepress begins to open, the draw ring surrounding the male die follows thepress upward stripping the part from the male die. When the part hasbeen lifted to the point of clearing the male die, the draw ring isrestrained from further travel and the part is blown off the ring andonto a conveyor by strategically placed air jets.

According to the present invention, a die system for cutting a piece ofsheet stock to create a blank and forming the blank to create acontainer includes first and second mating die halves and a cuttingpunch. The first and second die halves are configured to move togetherto form the container from the blank. The cutting punch extends aboutthe first die half and is movable therewith. The cutting punch isconfigured to cut the piece of sheet stock to create the blank. Movementof the die halves together causes the cutting punch to cut the blankfrom the piece of sheet stock and further movement of the die halvestogether causes the first and second die halves to form the containerfrom the blank.

In preferred embodiments, the first die half is a female die half andthe second die half is a male die half. The female and male die halvesare positioned substantially horizontally with the female die half beingpositioned vertically above the male die half. The male die half isstationary so that the female die half moves vertically downwardly tomate with the male die half to form the container and vertically awayfrom the male die half to release the container from between the femaleand male die halves.

The die system may also include a draw ring extending about the male diehalf. The draw ring is movable with the female die half relative to themale die half so that the blank is held between the draw ring and aperimetal surface of the first die half as the container is beingformed. The die system may also include a stripper ring extending aboutthe cutting punch and movable with the first die half. The stripper ringis configured to hold the piece of sheet stock in place as the sheetstock is being cut and the blank is being formed. The die system mayalso include a cutting ring extending about and spaced-apart from thesecond die half and positioned to lie opposite the stripper ring. Thecutting ring is configured to cooperate with the stripper ring to holdthe sheet stock between the stripper ring and the cutting ring. Thecutting ring is also configured to allow the cutting punch to extendbetween the second die half and the cutting ring to cut the sheet stock.

Additional features and advantages of the invention will become apparentto those skilled in the art upon consideration of the following detaileddescription of illustrated embodiments exemplifying the best mode ofcarrying out the invention as presently perceived.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description particularly refers to the following figures inwhich:

FIG. 1 is a side view of a die system in accordance with the presentinvention showing the die system having a frame and a pair of female andmale mating die halves mounted to the frame, the female and male diehalves being configured to receive a piece of sheet stock such aspaperboard therebetween so that the die halves can move together to cutthe sheet stock to create a blank and form the blank to create acontainer;

FIG. 2 is a front view of the die system of FIG. 1 showing the diesystem having three sets of female and male mating dies wherein threefemale die halves are mounted to an upper section of the frame and threemale die halves are mounted to a lower section of the frame;

FIGS. 3-6 are enlarged views of a portion of the die system of FIGS. 1and 2 showing the female and male die halves moving together to cut thepiece of sheet stock to create the blank and forming the blank to createthe container;

FIG. 3 is an enlarged view of a portion of the die system of FIGS. 1 and2 showing a piece of sheet stock positioned between the male die halfand the female die half with the female die half positioned inspaced-apart relation to the male die half;

FIG. 4 is a view similar to FIG. 3 showing movement of female die halfdownwardly toward the male die half such that the piece of sheet stockis held between a perimetal surface of the female die half and a drawring extending about the male die half and is also held between astripper ring extending about the female die half and a cutting ringextending about the draw ring;

FIG. 5 is a view similar to FIGS. 3 and 4 showing further movement ofthe female die half toward the male die half causing a cutting punchextending about the female die to cut the piece of sheet stock betweenthe draw ring and the cutting ring to create the blank and an outerperimetal portion of the blank being held between the perimetal surfaceof the female die half and the draw ring with the draw ring beingslightly compressed by the female die half to cause the draw ring tomove downwardly with the female die half relative to the male die half;

FIG. 6 is a view similar to FIGS. 3-5 showing further movement of thefemale die half toward the male die half causing the female and male diehalves to press together to form the blank into the container andshowing the outer perimetal portion of the container being held betweenthe perimetal surface of the female die and the draw ring with the drawring being further compressed by the female die half to cause the drawring to move further downwardly;

FIG. 7 is a view similar to FIGS. 3-6 showing movement of the female diehalf upwardly away from the male die half causing the container to beremoved from between the female and male die halves so that thecontainer is positioned within an opening formed in the piece of sheetstock as a result of the blank being cut from the piece of sheet stockand showing the container being moved by the piece of sheet stock as thesheet stock is advanced;

FIG. 8 is a sectional view taken along line 8—8 of FIG. 1 showing thedie system of FIG. 1 being configured to cut and form three containersand showing a second die system located upstream from the die system ofFIG. 1, the second die system being configured to cut and form twocontainers to minimize the amount of wasted sheet stock; and

FIG. 9 is a side view of the two die systems of FIG. 8.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring now to the drawings, FIGS. 1 and 2 illustrate a die system 10for cutting and forming a piece of sheet stock 11 in a single-pressaction to create one or more containers. Sheet stock 11 may be, forexample, Solid Bleached Sulfate (SBS) paperboard between 0.001-0.024inch (0.0254-0.6096 mm), although other sizes and types of sheet stockmay be used. The sheet stock 11, for example, may be recycledpaperboard, multiple webs of material, single-sided corrugatedpaperboard, or any other sheet stock from which a container may be made.In addition, the containers that are made from sheet stock 11 can be anyshape or size including circular or rectangular containers forcontaining sandwiches or the like.

As shown in FIG. 1, die system 10 includes a frame (or die set) 12, apair of upper and lower cooling plates 14, 16, a pair of upper and lowermaster mount plates 18, 20, and at least one cutting/forming die 22.Frame 12 includes an upper die shoe 28 for mounting of the upper dieparts (described below), a lower die shoe 30 for mounting of the lowerdie parts (described below), and a set of four of die posts 32 and fourdie post bushings 34 for connecting the upper die shoe 28 to the lowerdie shoe 30. The upper die shoe 28 and all the upper die parts mountedto it reciprocate up and down on the die posts 32 using the die postbushings 34 as a linear bearing. The lower die shoe 30 and all the lowerdie parts mounted to it preferably remain stationary, although it isunderstood that either die shoe could move with the other beingstationary or both die shoes could move together to cut and form acontainer in accordance with the present invention. Die post bushings 34are pressed into bored holes in the upper die shoe 28. Die posts 32 arepressed into bored holes in the lower die shoe 30. Frame 12 alsoincludes a plurality of die lift bearings 36 mounted to a plurality ofdie lifting cross members 38, as shown in FIGS. 1 and 2, which allow theupper and lower die parts to be easily removed from frame 12 asdiscussed below.

Upper and lower cooling plates 14, 16 are mounted to upper and lower dieshoes 28, 30, respectively, as shown in FIG. 1. Upper and lower coolingplates 14, 16 substantially span the width and length of the upper andlower die shoes 28, 30, as shown in FIGS. 1 and 2. Temperaturecontrolled liquid circulates through the upper and lower cooling plates14, 16 to keep the upper die shoe 28 at a temperature consistent withthe lower die shoe 30. This minimizes or eliminates heat expansion ofthe upper die shoe 28 relative to the lower die shoe 30 as the upper dieshoe 28 reciprocates on the die posts 32.

Upper and lower master mount plates 18, 20 are mounted to upper andlower cooling plates 14, 16, respectively. Upper and lower master mountplates 18, 20 substantially span the width and length of the upper andlower cooling plates 14, 16, as shown in FIGS. 1 and 2. The upper andlower master mount plates 18, 20 and the upper and lower cooling plates14, 16 preferably remain mounted to one another and to the frame 12 whenan individual die 22 needs to be changed or disconnected from die system10 for maintenance, replacement, or the like. However, the upper andlower master mount plates 18, 20 and all the dies 22 mounted to it mayalso be removed when the entire set of dies 22 mounted to master mountplates 18, 20 need to be changed or serviced. For example, die liftingbearings 36 project through cutouts in the lower die shoe 30 and lowercooling plate 16 to allow the upper and lower master mount plates 18, 20and connected cutting/forming dies 22 to be lifted up and rolled out ofthe press on the die lifting bearings 36 when die lift bearings 36 andcross member 38 are urged upwardly by a lifting force and the mastermount plates 18, 20 are unbolted from their respective die shoes 28, 30.Thus, upper and lower master mount plates 18, 20 allow dies 22 to bechanged individually or as a complete set.

Each die 22 includes an upper die section 40 and a lower die section 42mounted to upper and lower master mount plates 18, 20, respectively, asshown in FIGS. 1 and 2. Each upper die section 40 of each die 22includes a mounting flange 48, a backing plate 50 spaced-apart frommounting flange 48, and a backing ring 52 interconnecting mountingflange 48 and backing plate 50, as shown in FIG. 1. Mounting flange 48is bolted to upper master mount plate 18 and is a separate piece foreach individual cutting/forming die 22, as shown in FIG. 2. This allowsone or more dies 22 having upper and lower die sections 40, 42 to bemounted to master mount plates 18, 20. Backing ring 52 extendsdownwardly from mounting flange 48 to interconnect mounting flange 48and backing plate 50. An insulating material 54 is positioned withinbacking ring 52 between mounting flange 48 and backing plate 50 toprovide heat insulation for various die parts as described below.

Each upper die section 40 also includes a first die half 56 mounted tobacking plate 50, a heater retainer plate 58 mounted to backing plate 50and positioned within first die half 56, and a heater 60 positionedwithin first die half 56 and mounted to backing plate 50. The first diehalf 56 is preferably a female die half, as shown in FIGS. 1 and 3,having an outer surface 61, a concave inner surface 62 for forming acontainer, and a perimetal surface 64 interconnecting outer surface 61and inner surface 62. The outer surface 61 is formed to receive heaterretainer plate 58 and heater 60, as shown in FIG. 3. The heater retainerplate 58 holds the heater 60 in position against first die half 56. Theheater 60 is configured to heat first die half 56 to a temperature of125° F. to 500° F. (51.67° C. to 260° C.) depending upon the type ofcontainer being formed and the type of sheet stock 11 being used.

Each upper die section 40 also includes a cutting punch 68 mounted tobacking ring 52 and extending about first die half 56 and a stripperring 70 coupled to backing ring 52 via a pair of pressure cylinders 72,74 and extending about cutting punch 68. Cutting punch 68 is configuredto cut the piece of sheet stock 11 to create a blank from the sheetstock 11 and stripper ring 70 is configured to hold the piece of sheetstock in place during the cutting and forming of the sheet stock 11 tocreate the container.

Cutting punch 68 is spaced apart from first die half 56 so that an airgap 76 minimizes or prevents heat from being transferred from heater 60through first die half 56 to cutting punch 68 causing undesirableexpansion and/or contraction of cutting punch 68 relative to first diehalf 56. In addition, the insulating material 54 positioned withinbacking ring 52 minimizes or prevents heat transfer from occurringbetween the female die half heater 60 and the upper parts of the diesystem 10, which would then transfer heat to cutting punch 68. This heattransfer is further thwarted by having backing ring 52 preferably bemade from stainless steel which provides natural resistance to heattransfer while providing back up strength to cutting punch 68. Backingplate 50 may also be made of stainless steel to further reduce heattransfer and provide back up strength between the insulating material 54and the female die half 56.

Stripper ring 70 is coupled to backing ring 54 using a pair of pressurecylinders 72, 74 (shown in FIG. 1) and a pair of retainer bolts 78,80(shown in FIG. 2). Stripper ring 70 is configured to hold sheet stock 11in place during cutting and forming of sheet stock 11 into one or morecontainers. Pressure cylinders 72, 74 are preferably air cylindersconfigured to urge stripper ring 70 downwardly in a controlled manner.However, pressure cylinders 72, 74 can also be any fluid cylinder, suchas liquid or gaseous cylinders, or any other spring-like device forbiasing stripper ring 70 downwardly.

Stripper ring 70 is held in position slightly below the level of thecutting punch 68 by stripper ring retainer bolts 78, 80 (shown in FIG.2) and is urged downward by pressure cylinders 72, 74. The retainerbolts 78, 80 and pressure cylinders 72, 74 are held in place by pressurecylinder brackets 81, 82 and retainer bolt brackets 83, 84 (shown inFIGS. 1 and 2). All of these brackets 81, 82, 83, 84 are bolted to thestainless steel backing ring 52. The operation of stripper ring 70,cutting punch 68, and first die half 56 to cut and form the sheet stockinto a container will be discussed in detail below.

Referring now to the lower die section 42 of each die 22, each lower diesection 42 includes a mounting flange 88, a backing plate 90spaced-apart from mounting flange 88, and a backing ring 92interconnecting mounting flange 88 and backing plate 90, as shown inFIG. 1. Mounting flange 88 is bolted to lower master mount plate 20 andis a separate piece for each individual cutting/forming die 22, as shownin FIG. 2. Backing ring 92 extends upwardly from mounting flange 88 tointerconnect mounting flange 88 and backing plate 90. An insulatingmaterial 94 is positioned within backing ring 92 between mounting flange88 and backing plate 90 to provide heat insulation for various parts asdescribed below.

Each lower die section 42 also includes a second die half 96 mounted tobacking plate 90, a heater retainer plate 98 mounted to backing plate 90and positioned within second die half 96, and a heater 100 positionedwithin second die half 96 and mounted to backing plate 90. The seconddie half 96 is preferably a male die half, formed to receive heaterretainer plate 98 and heater 100, as shown in FIGS. 1 and 3. The heaterretainer plate 98 holds the heater 100 in position against second diehalf 96. The heater 100 is configured to heat second die half 96 to atemperature of 125° F. to 500° F. (51.67° C. to 260° C.) depending uponthe type of container being formed and the type of sheet stock 11 beingused.

Each lower die section 42 also includes a draw ring 110 extending aboutsecond die half 96 and a cutting ring 112 extending about draw ring 110,as shown in FIGS. 1-3. Draw ring 110 is configured to cooperate withperimetal surface 64 of female die half 56, as described below, to holdthe blank taut as the female and male die halves 56, 96 are mating toform the container. Cutting ring 112 is configured to cooperate withstripper ring 70 to hold the sheet stock 11 in place during the cuttingand forming process and is configured to cooperate with cutting punch 68to cut the blank from the sheet stock 11.

Draw ring 110 surrounds the male die half 96 and is held in position bynarrow plates (not shown) extending through slots (not shown) in thecutting ring 112. As described in more detail below, draw ring 110 isconfigured to move downwardly and upwardly with female die half 56relative to male die half 96 as the container is being formed to holdthe blank of sheet stock in place during the forming process. Draw ring110 is urged upwardly by pressure cylinders 114, 116 and the travel ofdraw ring 110 is limited by the slots in cutting ring 112. Pressurecylinders 114, 116 are similar to pressure cylinders 72, 74 and can bevirtually any type of spring-like biasing member.

Cutting ring 112 is spaced apart from draw ring 110 to create an air gap118 that minimizes or prevents heat from being transferred from heater100 through second die half 96 to cutting ring 112 causing undesirableexpansion and/or contraction of cutting ring 112 relative to second diehalf 96. In addition, the insulating material 94 positioned withinbacking ring 92 minimizes or prevents heat transfer from occurringbetween male die half heater 100 and the lower parts of die system 10,which would then transfer heat to cutting ring 112. This heat transferis further thwarted by having backing ring 92 preferably be made fromstainless steel which provides natural resistance to heat transfer whileproviding back up strength to cutting ring 112. Backing plate 90 mayalso be made of stainless steel to further reduce heat transfer andprovide back up strength between the lower insulating material 94 andmale die half 96.

Die system 10 of the present invention operates as shown in FIGS. 3-8and described below. First, as shown in FIG. 3, a web (or multiple websstacked one on top of each other) of sheet stock such as paperboard 11is fed into die system 10 in a direction indicated by arrow 124 via aseparate feeding mechanism or pull-off system associated with the pressin which the die system is mounted. This web of paperboard 11 ispositioned between upper and lower die sections 40,42 with paperboard 11ultimately resting on cutting ring 112, draw ring 110 and male die half96, as shown in FIG. 3. Then, depending upon the type of container beingformed and the type of paperboard, female die half 56 and/or male diehalf 96 may be heated to a temperature of 125° F. to 500° F. (51.67° C.to 260° C.) via female die half heater 60 and/or male die half heater100, respectively.

When paperboard 11 is in position, as shown in FIG. 3, a signal is givento die system 10 to begin the cycle. Upper die section 40 begins todescend in a direction indicated by arrows 127. As shown in FIG. 4,stripper ring 70 engages paperboard 11 first to secure paperboard 11between stripper ring 70 and cutting ring 112. This prevents anymovement of paperboard 11 during the cutting and forming process. Upperdie section 40 continues to descend and within fractions of an inch (orfractions of a centimeter) cutting punch 68 begins to shear paperboard11 between an outer edge 128 of cutting punch 68 and an inner edge 130of cutting ring 112, as shown in FIG. 5. Inner edge 130 of cutting ring112 may be ground in a very slight bevel to provide shear to thiscutting action and to reduce the amount of force required to cutpaperboard 11.

As upper die section 40 continues to descend after paperboard 11 is cut,perimetal surface 64 of female die half 56 holds the blank of paperboard11 against draw ring 110, as shown in FIG. 5. Draw ring 110 is urgedupwardly under pressure by pressure cylinders 114, 116 acting as springsand holding paperboard 11 tightly against perimetal surface 64 of femaledie half 56. This force of holding paperboard 11 between female die half56 and draw ring 110 holds paperboard 11 taut as female die half 56begins to form paperboard 11 over male die half 96, thereby preventingwrinkles in paperboard 11 from forming as the diameter of the blank isreduced as shown by distances 132, 134 in FIGS. 5 and 6, respectively.This force is adjustable by varying the pressure to the pressurecylinders 114, 116. If wrinkles are forming in the container, then thepressure can be increased. If the paperboard is tearing, then it isbeing held too tightly and the pressure can be reduced. While paperboard11 is being cut and formed, stripper ring 70 and cutting ring 112continue to hold paperboard 11 outside of the cutting edge. Stripperring 70 is urged against paperboard 11 by stripper ring air cylinders72, 74 which act as springs and compress as upper die section 40descends, as shown in FIG. 6.

Because the paperboard is held in tension at all times during and afterbeing cut, and is not transferred to another station for forming, thereis no opportunity for misalignment of the blanks relative to die halves56, 96 resulting in waste and jam-ups. In addition, because female diehalf 56 is pressed downwardly on male die half 96, the final product(such as a paper plate or container) is formed upside down which ispreferable for ejection and stacking reasons, as discussed below.

Upper die section 40 continues to descend and female die half 56continues to form the blank of paperboard over and around male die half96. When the press reaches its maximum closed position, female die half56 and male die half 96 have completely closed on paperboard 11, asshown in FIG. 6. In this position, female and male die halves 56, 96hold the container under the tremendous force generated by die system 10of approximately 6,000 lbs. to 16,000 lbs. per lane and draw ring 110has moved a maximum distance 140 relative to cutting ring 112 and maledie half 96. Die system 10 then dwells in this closed position for atime period of about ⅓ second to 1 second in order to allow the heatfrom the forming sections to iron the container into the shape of thedie.

As the press begins to open back up, female die half 56 begins to liftoff male die half 96. A very short burst of air may be directed throughvent holes (not shown) in male die half 96 as soon as female die half 56begins its ascent in order to ensure that the container releases frommale die half 96. Because draw ring 110 is urged upwardly by aircylinders 114, 116 acting as springs, the upside-down container islifted off male die half 96 by its flange which is still in contact withdraw ring 110. The container flange is trapped between draw ring 110 andperimetal surface 64 of female die half 56. As draw ring 110 reaches theend of its travel, a very short blast of air may be directed throughvent holes in inner surface 62 of female die half 56 to ensure thecontainer stays on male die half 96 and does not follow female die half56 up as it ascends further. At approximately the same time as femaledie half 56 releases contact with draw ring 110 through the containerflange, stripper ring 70 releases paperboard web 11 which now has a hole142 (shown in FIG. 7) cut in it from where the blank was cut.

At this point in the cycle, the container is resting with its flange ondraw ring 110 and paperboard web 11 is resting on top of cutting ring112 as shown illustratively in FIG. 7. As soon as upper die section 40has ascended far enough that female die section 56 has cleared thecontainer bottom, the feed mechanism indexes the web. As paperboard web11 is indexed, the leading edge is lifted somewhat, as shown in FIG. 7.A side wall defining hole 142 in the paperboard web where the blank wascut bumps into the container urging it forward. Near the end of the feedcycle, a brief blast of air is directed downwardly at an angle to theleading edge of the container. The container is directed in a downwardpath indicated by arrow 124 (FIG. 7) as the web of paperboard 11 isdirected along a horizontal plane. This then allows the container to beseparated from the web of paperboard by traveling through hole 142 inthe web of paperboard 11 which is naturally larger than the formedcontainer, as shown in FIG. 8. The container can then exit die system 10downwardly through a product slide 150, shown in FIG. 9. As thecontainers exit die system 10, they are conveyed to another area of themachine where they are counted, stacked and presented to the operatorfor packaging.

As shown in FIGS. 8 and 9, die system 10 may be combined with anupstream die system 210 positioned upstream from die system 10 (i.e., ina direction opposite feed direction 124). Die system 210 has twocutting/forming dies 22. As shown in FIG. 9, paperboard 11 first entersdie system 210 through a web-guide system 148 so that two containers canbe cut and formed using the two cutting/forming dies 22 of die system210 shown in FIG. 8. Paperboard 11 is then indexed through an in-feedsection 152 and into die system 10. Three more containers are cut andpress-formed by the three cutting/forming dies 22 of die system 10 andthe scrap skeleton of paperboard 11 then exits through an out-feedsection 154. After out-feed section 154, the scrap paperboard is cutinto pieces and discharged. Although the current configuration shows twodie systems 10, 210 having five cutting/forming dies 22, any combinationof die systems and cutting/forming dies can be used to minimize theamount of scrap material that is produced and any shape container may beformed. The five cutting/forming dies 22 (three dies 22 of die system 10and two dies 22 of second die system 210) are spaced to maximize the useof paperboard 11 so that waste is minimized, as shown in FIG. 8.

Two illustrative drive systems 160 for reciprocating upper die shoes 28of die systems 10, 210 up and down relative to lower die shoes 30 of diesystems 10, 210 is shown in FIG. 9. Each drive system 160 includes amounting member 162, a first toggle 164, a second toggle 166, and adrive cylinder 168. Mounting member 162 is mounted to a beam 170 that isseparate and spaced-apart from frame 12 of each die system 10, 210.First toggle 164 is coupled to mounting member 162 and to drive cylinder168, as shown in FIG. 9. Second toggle 166 is coupled to upper die shoe28 and to drive cylinder 168. Drive cylinder 168 reciprocates along ahorizontal path so that first and second toggles 164, 166 move upper dieshoe 28 up and down relative to lower die shoe 30, as shownillustratively in FIG. 9.

The die system of the present invention has fewer moving parts andsimpler operation. It does not require double action press and both thecutting and forming steps are performed in a single press action. Itrequires shorter stroke press thereby conserving energy and componentlife. It has an adjustable die forming dwell time using hydraulic ramwith less effect on output speeds. It also configures the dies in twogroups or die systems to minimize paper scrap in round blank designs. Italso configures one or more separate dies in two die systems minimizingpress component size by a power of four (4) or more due to smallerrequired moment of inertiIa. In addition, die shoe temperature controlallows broader material variance for more flexible part manufacturing.Also, independently adjustable die opening and closing speeds and partforming dwell times optimize output speeds. Furthermore, the containeris blanked and formed in same location eliminating transfer problems andthe dies are mounted on a flat, horizontal bed resulting in less wear onpress and die parts. Finally, the dies are positively mounted so nomisalignment can occur from jam ups.

Although the invention has been described in detail with reference to acertain illustrated embodiment, variations and modifications existwithin the scope and spirit of the invention as described and as definedin the following claims.

What is claimed is:
 1. A press system for cutting and forming aplurality of containers from sheet stock, the press system comprising:first and second presses through which the sheet stock is fed in a feeddirection, each press comprising a plurality of die systems forsequentially cutting the sheet stock to create a blank and forming theblank to create a separate container by each of said first and secondpresses, each die system comprising: first and second mating die halvesconfigured to move together to form the container from the blank, and acutting punch extending about the first die half and movable therewith,the cutting punch being configured to cut the piece of sheet stock tocreate the blank, movement of the die halves together causing thecutting punch to cut the blank from the piece of sheet stock and furthermovement of the die halves together causing the first and second diehalves to form the container from the blank the first press beingpositioned upstream from the second press and the die systems comprisingthe first press being positioned and arranged to cut blanks from thesheet stock in a first pattern and form the blanks into containers,leaving a modified web of sheet stock, the die systems comprising thesecond press being positioned and arranged to subsequently cut blanksfrom the modified web of sheet stock in a second pattern and form theblanks into containers whereby the first and second patterns are spacedto maximize the use of the sheet stock.
 2. The apparatus of claim 1further comprising an indexer and wherein the first press furthercomprises an out-feed section feeding the modified web of sheet stock tothe indexer, and the second press further comprises an in-feed sectionfed the modified web of sheet stock by the indexer.
 3. The apparatus ofclaim 2 wherein the indexer indexes the modified web of sheet stock toposition the modified web of sheet stock so that blanks are cut from themodified web of sheet stock and formed into containers by the die systemof the second press.
 4. A press system for cutting and forming aplurality of containers from sheet stock consisting of material, thepress system comprising: a first press through which the sheet stock isfed comprising: a plurality of die systems, each die system comprising:first and second mating die halves configured to move together to form acontainer from a blank, and a cutting punch extending about the firstdie half and movable therewith, the cutting punch being configured tocut the sheet stock to create the blank leaving modified sheet stock,movement of the die halves together causing the cutting punch to cut theblank from the sheet stock and further movement of the die halvestogether causing the first and second die halves to form the containerfrom the blank; and an out-feed system through which said modified sheetstock is fed, a second press comprising an in-feed system coupled to theout-feed system of the first press through which the modified sheetstock is fed and a plurality of die systems, each die system comprising:first and second mating die halves configured to move together to form acontainer from a blank, and a cutting punch extending about the firstdie half and movable therewith, the cutting punch being configured tocut the modified sheet stock to create the blank leaving scrap skeletonsheet stock, movement of the die halves together causing the cuttingpunch to cut the blank from the modified sheet stock and furthermovement of the die halves together causing the first and second diehalves to form the container from the blank; and wherein the first andsecond presses are designed and arranged to minimize the material in thescrap skeleton sheet stock.
 5. The apparatus of claim 4 and furthercomprising an indexer receiving modified sheet stock from the out-feedsystem of the first press and feeding modified sheet stock to thein-feed system of the second press.